Input shaft - adjust

Make

Volkswagen

Model

Polo Mk4

Section

5-speed manual gearbox 02R › Gearbox,mechanics,gears,shafts,internal operation › Input shaft - adjust

Clutch and gearboxInput shaft - adjust

Input shaft - adjust (Determining input shaft adjustment shim)

Special tools and workshop equipment required

t	Clock mounting -VW 387-

t	Final measurement plate -VW 385/17-

t	Pressure disc -VW 510-

t	Pressure disc -VW 447 i-

t	Pressure pin -VW 407-

t	5 - 50 Nm Torquemeter -VAG 1331-

t	Dial gauge

It is only necessary to readjust the input shaft when the following components are renewed: t  Gearbox housing t  Clutch housing t  Input shaft t  4th gear wheel or the t  Taper roller bearing Adjustment overview → Chapter

–  Press taper roller bearing outer race, without shim, into gearbox housing onto stop. –  Install input shaft in clutch housing and assemble gearbox housing. Tighten hexagon bolts with 25Nm + 90°.

–  Fit measuring appliance and D.T.I. in clutch housing (large taper roller bearing in gearbox housing). –  Before taking any measurements, rotate input shaft to allow bearings to settle. Preload dial gauge to 1 mm and set to “0”.   Note This preparation is to be repeated for each subsequent measurement, otherwise the gauge will not return to the starting position.

–  Press input shaft in direction of D.T.I. -arrow-. –  Read off and note clearance indicated on D.T.I. (example 1.21).   Note D.T.I. does not return to original position –  Determine thickness of shim from table → Chapter (Example 1.175). –  Remove input shaft and press taper roller bearing outer race out of gearbox housing using -VW 447i-. –  Press taper roller bearing outer race together with the 1.175 shim into gearbox housing using -VW 510- –  Assemble gearbox housing and tighten hexagon head bolts to 25 Nm and then turn 90° further

07 Transmission